Influence of Microporous Layers on Interfacial Properties, Oxygen Flow Distribution, and Durability of Proton Exchange Membrane Water Electrolyzers

The efficient and cost-effective production of green hydrogen is essential to decarbonize heavily polluting sectors such as transportation and heavy manufacturing industries such as metal refining. Polymer electrolyte membrane water electrolysis (PEMWE) is the most promising and rapidly maturing technology for producing green hydrogen at a scale and on demand. However, substantial cost reduction by lowering precious metal catalyst loadings and efficiency improvement is necessary to lower the cost of the produced hydrogen. Porous transport layers (PTLs) play a major role in influencing the PEMWE efficiency and catalyst utilization. Several studies have projected that the use of microporous layers (MPLs) on PTLs can improve the efficiency of PEMWEs, but very limited literature exists on how MPLs affect anodic interfacial properties and oxygen transport in PTLs. In this study, for the first time, we use X-ray microtomography and innovative image processing techniques to elucidate the oxygen flow patterns in PTLs with varying MPL thicknesses. We used stained water to improve contrast of oxygen in PTLs and demonstrate visualization of time averaged oxygen flow patterns. The results show that PTLs with MPLs significantly improve interfacial contact by almost 20% as compared to single layer sintered PTL. For the single layer PTL without MPL, the pore volume utilization for oxygen flow is low and the oxygen follows a viscous fingering flow regime. With MPLs, the pore volume utilization is higher, and the number of oxygen transport pathways is increased significantly. MPLs were also shown to suppress capillary fingering and transition oxygen flow to the viscous fingering regime, which has been proven to decrease site masking effects. Finally, durability tests showed the least voltage degradation for thin MPL and thicker MPLs run into mass transport limitations. Based on these findings, PTL/MPL design optimization strategies are proposed for enabling low catalyst loadings and improving durability.